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5.2 Waste Heat Recovery Opportunity Areas Based on estimates of waste heat losses in selected applications, several trends were identified regarding opportunity areas and RD&D needs for waste heat recovery. Opportunity areas are listed below and further elaborated in Sections 5.35.6. Key opportunity areas: 5.3 • • • • Lowtemperature waste heat sources Based on a 77°F [25°C] reference, most unrecovered waste heat is at low temperatures. About 60% of waste heat losses are at temperatures below 450°F [230°C]. Systems already including waste heat recovery that can be further optimized to reduce heat losses The extent of heat recovery from existing systems is often constrained by costs and temperature limits for the heat recovery system. In many cases, such as cement preheater kilns and recuperative glass furnaces, exhaust gases exiting the recovery device are still in the medium to hightemperature range. This represents an opportunity for additional waste heat recovery. Opportunities are also available to maximize the quality of heat recovered, since facilities often use dilution air to lower the temperature of waste heat streams. Hightemperature systems where heat recovery is less common There are market segments where waste heat recovery is less common; this is due to barriers such as chemical constituents in exhaust gases that interfere with heat exchange, as well as limitations on economies of scale for smaller waste heat streams. Alternate waste heat sources typically not considered for waste heat recovery This study focused on combustion and process exhaust gases. However, alternate sources of waste heat were also found to be significant. These alternates include heat radiated, convected, and conducted from heated products (e.g., cast steel, hot cokes), as well as heat lost in aluminum cell sidewalls and after pyroprocesses where slag or after materials are solidified to protect the vessel walls. Waste Heat Opportunity Figure 30 displays estimated waste heat losses in different temperature groups. The temperature groups are defined as: High Medium Low 1200oF [650°C] and higher 450oF [230°C] to 1,200oF [650°C] 450oF [230°C] and lower 150 Based on a reference temperature of 77°F [25°C], approximately 60% of waste heat analyzed is low temperature heat below 450°F [230°C], and nearly 90% of waste heat is below 600°F [316°C]. It is already wellknown that lowtemperature heat is abundant; however a unique element in this study is its analysis of the work potential of waste heat, which allows a better comparison of waste heat at different temperatures. As shown in Table 21 and Figure 30, the work potential of lowtemperature waste heat (based on a 77°F reference) exceeds that of medium and hightemperature heat. Therefore, even when accounting for the lesser value of lowtemperature heat, the sheer magnitude of lowtemperature heat available makes it worthy of further investigation. The analysis above is based on the quantity of heat estimated using a reference temperature of 77°F [25°C]. This reflects the maximum heat recoverable if exhaust gases are cooled to room temperature. However, many facilities only cool exhaust gases to about 300°F [150°C] in order to prevent flue gas condensation. Based on a 300°F [150°C] reference, more heat is recoverable in the medium to high 54 PDF Image | Waste Heat to Energy Tech Opportunities in US Industry
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